Toro PROLINE 44409 Service Manual

Mid-size mower

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Form No. 3431-988 Rev A

PROLINE® Service Manual

Published: May 2020

Original Instructions (EN)

8111 Lyndale Avenue South

Bloomington, MN 55420

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Summary of Contents for Toro PROLINE 44409

Page 1 Form No. 3431-988 Rev A PROLINE® Service Manual Published: May 2020 © 2020—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
Page 2 Revision History Revision History Page 2 PROLINE® Service Manual 3431-988 Rev A...
Page 3 The Toro Company RLC/SWS Customer Care Department 8111 Lyndale Avenue South Bloomington, MN 55420 The Toro Company reserves the right to change product specifications or make changes to this manual without notice. PROLINE® Service Manual Page 3 Preface...
Page 4 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • Installing safety equipment (shields, guards, seat belts, brakes, and R.O.P.S. components) that may have been removed •...
Page 5 Table of Contents Preface ........................ 3 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–7 Chapter 3: Troubleshooting ................3–1 General Troubleshooting ................3–3 Chapter 4: Engine ................... 4–1 General Information ..................
Page 6 Preface Page 6 PROLINE® Service Manual 3431-988 Rev A...
Page 7 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Think Safety First ..........................1–2 PROLINE® Service Manual Page 1–1 Safety 3431-988 Rev A...
Page 8 Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow.
Page 9 Think Safety First (continued) Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Battery gases can explode. Keep cigarettes, sparks and flames away from the battery. Avoid injury due to inferior parts… Use only original equipment parts to ensure that important safety criteria are met. Avoid injury to bystanders…...
Page 10 Think Safety First (continued) The proper class of fire extinguisher should be used in case of fire. Class A extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish.
Page 11 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Torque Specifications ........................... 2–7 Equivalents and Conversions......................2–12 U.S. to Metric Conversions ......................2–13 PROLINE® Service Manual Page 2–1 Specifications and Maintenance 3431-988 Rev A...
Page 12 NGKBPR4ES Spark Plug Gap 0.76 mm (0.030 inches) Ignition Coil Air Gap 0.3 mm (0.011 inches) Battery 195 CCA Traction Drive Controls Toro Twin Levers Transmission Hydro-Gear ZT-2800 Transmission 20W–50 Engine oil Lubricant Parking Brake Standard Equipment Ground Speed Infinitely Variable...
Page 13 NGKBPR4ES Spark Plug Gap 0.76 mm (0.030 inches) Ignition Coil Air Gap 0.3 mm (0.011 inches) Battery 195 CCA Traction Drive Controls Toro Twin Levers Transmission Hydro-Gear ZT-3100 Transmission 20W–50 Engine oil Lubricant Parking Brake Standard Equipment Ground Speed Infinitely Variable...
Page 14 Spark Plug Gap 0.76 mm (0.030 inches) Ignition Coil Air Gap 0.3 mm (0.011 inches) Battery 195 CCA Traction Drive Controls Toro Twin Levers Transmission Hydro-Gear ZT-3100 Transmission Lubricant 20W–50 Engine oil Parking Brake Standard Equipment Ground Speed Infinitely Variable...
Page 15 NGKBPR4ES Spark Plug Gap 0.76 mm (0.030 inches) Ignition Coil Air Gap 0.3 mm (0.011 inches) Battery 195 CCA Traction Drive Toro Twin Levers Controls Transmission Hydro-Gear ZT-2800 Hydro-Gear ZT-3100 PROLINE® Service Manual Page 2–5 Specifications and Maintenance: Specifications 3431-988 Rev A...
Page 16 Transmission Lubricant 20W–50 Engine oil Parking Brake Standard Equipment Ground Speed Infinitely Variable Drive Belt HA Section with Aramid (Kevlar) cords Wheels and Tires Front Castor Tires 9 x 3.5 - 4 inches, smooth tread, 11 x 4 - 5 inches, smooth tread, semi-pneumatic semi-pneumatic Front Castor Fork...
Page 17 Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.
Page 18 Metric Bolts and Screws g272209 Figure 2 Class 8.8 Class 10.9 Specifications and Maintenance: Torque Specifications Page 2–8 PROLINE® Service Manual 3431-988 Rev A...
Page 19 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 5, & 8 Studes & Sems with Studs & Sems with Regular Studs &...
Page 20 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Height Nuts (Class 10 or stronger Nuts) in-lb N •...
Page 21 SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 1/2 - 13 UNC 75 ±...
Page 22 Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals Fractions Decimals 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32 0.9375...
Page 23 U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Linear Measurement Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Area Square Inches...
Page 24 Specifications and Maintenance: Torque Specifications Page 2–14 PROLINE® Service Manual 3431-988 Rev A...
Page 25 Chapter 3 Troubleshooting Table of Contents General Troubleshooting ........................3–3 PROLINE® Service Manual Page 3–1 Troubleshooting 3431-988 Rev A...
Page 26 GEARS The Systematic approach to defining, diagnosing and solving problems. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...
Page 27 General Troubleshooting Problem Possible Cause Corrective Action The starter does not crank The blade control switch (PTO) is Move the blade-control switch (PTO) to engaged. the disengaged position. The parking brake is not engaged. Move the brake arm to the engaged position.
Page 28 General Troubleshooting (continued) Problem Possible Cause Corrective Action The engine overheats The engine load is excessive. Reduce the ground speed or raise height-of-cut. The oil level in the crankcase is low. Add oil to the crankcase. The cooling fins and the air passages Remove the obstruction and thoroughly above the engine are plugged.
Page 29 General Troubleshooting (continued) Problem Possible Cause Corrective Action The clutch does not engage There is a low voltage supply at the Check the coil resistance, battery clutch. charge, charging system, and wiring connections and replace parts if necessary. The coil is damaged. Replace the clutch.
Page 30 Troubleshooting: General Troubleshooting Page 3–6 PROLINE® Service Manual 3431-988 Rev A...
Page 31 Chapter 4 Engine Table of Contents General Information ..........................4–2 Service and Repairs ..........................4–3 Engine Replacement.......................... 4–7 Carbon Canister Replacement......................4–18 Air Cleaner Replacement ......................... 4–18 Muffler Replacement ........................4–20 Fuel Tank Assembly Replacement ....................4–31 PROLINE® Service Manual Page 4–1 Engine 3431-988 Rev A...
Page 32 General Information Kawasaki is the only engine offered for this machine. Engine: General Information Page 4–2 PROLINE® Service Manual 3431-988 Rev A...
Page 33 Service and Repairs Engine Assembly 1 (36 Inch and International Models) g311924 Figure 3 Fuel Hose Clamp Emissions Hose Fuel Tank Asm Fuel Valve Fuel Filter Fuel Hose Fuel Hose Tee and Check PROLINE® Service Manual Page 4–3 Engine: Service and Repairs 3431-988 Rev A...
Page 34 Engine Assembly 2 (48, 54, and 60 Inch Standard & 48 Inch International) g311925 Figure 4 Emissions Hose Fuel Hose Fuel Hose Tee and Check Fuel Valve Fuel Filter Clamp Fuel Hose Fuel Tank Asm Engine: Service and Repairs Page 4–4 PROLINE®...
Page 35 Engine Assembly 3 (36 Inch Carb) g311926 Figure 5 Fuel Hose Straight Fitting Clamp 800cc Carbon Canister Fuel Tank Asm Canister Vent Hose Emission Hose Formed Vent Hose Carbon Canister Bracket Vacuum Control Valve Fuel Valve Formed Vent Hose Fuel Hose Formed Vent Hose Fuel Hose PROLINE®...
Page 36 Engine Assembly 4 (48 and 54 Inch Premium & 48 Inch Carb Models) g320688 Figure 6 Emissions Hose Straight Fitting Fuel Hose 800cc Carbon Canister Fuel Valve Canister Vent Hose Fuel Hose Formed Vent Hose Clamp Vacuum Control Valve Fuel Tank Asm Formed Vent Hose Carbon Canister Bracket Formed Vent Hose...
Page 37 Engine Replacement Engine Removal WARNING Avoid inhaling exhaust fumes and never run an engine in a closed building or confined area. 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2.
Page 38 Engine Removal (continued) g311057 Figure 8 5. Remove the deck belt from the PTO clutch. g311058 Figure 9 6. Disconnect the engine harness from the machine harness. Engine: Service and Repairs Page 4–8 PROLINE® Service Manual 3431-988 Rev A...
Page 39 Engine Removal (continued) g311059 Figure 10 7. Remove the positive battery cable to the starter. g311098 Figure 11 8. Remove the ground battery cable to the engine ground. 9. Turn the fuel shut-off valve to the “OFF” position. PROLINE® Service Manual Page 4–9 Engine: Service and Repairs 3431-988 Rev A...
Page 40 Engine Removal (continued) g311099 Figure 12 10. Cut the 2 zip ties securing the vent hose, carbon canister hose, and fuel supply hose. Loosen the hose clamp on the fuel supply hose. Remove the fuel supply hose from the fuel pump. 11.
Page 41 Engine Removal (continued) g311100 Figure 14 15. Remove the bolt securing the PTO clutch to the machine. Remove the PTO clutch. 16. Remove the idler spring for the drive belt. g311101 Figure 15 17. Remove the drive belt from the drive pulley. Remove the drive pulley. PROLINE®...
Page 42 Engine Removal (continued) g311102 Figure 16 18. Remove the 4 bolts securing the engine to the frame. g311103 Figure 17 WARNING Heavy object, to avoid muscle strain or back injury, use lifting aids and proper lifting techniques when removing or replacing heavy objects.
Page 43 Engine Installation WARNING Heavy object, to avoid muscle strain or back injury, use lifting aids and proper lifting techniques when removing or replacing heavy objects. 1. Using an appropriate lifting device, install the engine onto the machine. 2. Reapply Loctite. Install the 4 bolts securing the engine to the frame. Torque to 40 N •...
Page 44 Engine Installation (continued) g311102 Figure 19 5. Install the idler spring to the drive belt. g311101 Figure 20 6. Align the keyway. Install the PTO clutch. Reapply Loctite and secure with a bolt. Torque bolt to 74 N • m (55 ± 5 ft-lb). 7.
Page 45 Engine Installation (continued) g311100 Figure 21 8. Install the strap securing the carbon canister hose. 9. Place the throttle lever into the detent position, engine should be at 3600 rpm. Connect the throttle and choke linkages. g311104 Figure 22 10. Install the vent hose to the engine take. Install 2 zip ties securing the vent hose and fuel hose going to the carburetor.
Page 46 Engine Installation (continued) g311099 Figure 23 13. Install the ground battery cable to the engine ground. 14. Install the positive battery cable to the starter. g311098 Figure 24 15. Connect the engine harness to the machine harness. Engine: Service and Repairs Page 4–16 PROLINE®...
Page 47 Engine Installation (continued) g311059 Figure 25 16. Install the deck belt to the PTO clutch. g311058 Figure 26 17. Install the spring to the deck idler. PROLINE® Service Manual Page 4–17 Engine: Service and Repairs 3431-988 Rev A...
Page 48 Engine Installation (continued) g320690 Figure 27 18. Install the deck guard to the frame. Install the 2 pull-down straps to the deck guard. 19. Connect the positive battery cable first, then the negative battery cable to the battery. Carbon Canister Replacement Carbon Canister Removal 1.
Page 49 Air Cleaner Removal (continued) g311184 Figure 28 4. Remove the 4 bolts from the retaining bracket to the bracket mounted on the engine. g311185 Figure 29 5. Remove the retaining bracket. 6. Remove the air cleaner assembly from the machine. Air Cleaner Installation 1.
Page 50 Air Cleaner Installation (continued) 2. Install the retainer bracket onto the machine. Secure with 4 bolts. Torque bolts to 60 N • m (52 in-lb). g311185 Figure 30 3. Tighten the worm clamp on the intake tube to the take. g311184 Figure 31 4.
Page 51 Muffler Removal (continued) 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery. 3. Remove the 2 pull-down straps from the deck guard. Remove the deck guard from the frame. g310218 Figure 32 4.
Page 52 Muffler Removal (continued) g311058 Figure 34 6. Disconnect the engine harness from the machine harness. g311059 Figure 35 7. Remove the positive battery cable to the starter. Engine: Service and Repairs Page 4–22 PROLINE® Service Manual 3431-988 Rev A...
Page 53 Muffler Removal (continued) g311098 Figure 36 8. Remove the ground battery cable to the engine ground. g311099 Figure 37 9. Cut the 2 zip ties securing the vent hose, carbon canister hose, and fuel supply hose. Loosen the hose clamp on the fuel supply hose. Remove the fuel supply hose from the fuel pump.
Page 54 Muffler Removal (continued) g311104 Figure 38 12. Remove the strap securing the carbon canister hose. 13. Disconnect the PTO clutch from the wiring harness. g311100 Figure 39 14. Remove the bolt securing the PTO clutch to the machine. Remove the PTO clutch.
Page 55 Muffler Removal (continued) g311101 Figure 40 16. Remove the drive belt from the drive pulley. Remove the drive pulley. g311102 Figure 41 17. Remove the 4 bolts securing the engine to the frame. PROLINE® Service Manual Page 4–25 Engine: Service and Repairs 3431-988 Rev A...
Page 56 Muffler Removal (continued) g311103 Figure 42 WARNING Heavy object, to avoid muscle strain or back injury, use lifting aids and proper lifting techniques when removing or replacing heavy objects. 18. Using an appropriate lifting device, remove the engine from the machine. 19.
Page 57 Muffler Installation (continued) g311102 Figure 43 6. Install the idler spring for the drive belt. g311101 Figure 44 7. Install the PTO clutch. Secure with a bolt. Torque bolt to 67 N • m (55 ± 5 ft-lb). 8. Connect the PTO clutch to the wiring harness. PROLINE®...
Page 58 Muffler Installation (continued) g311100 Figure 45 9. Install the strap securing the carbon canister hose. 10. Connect the throttle and choke linkages. g311104 Figure 46 11. Install the vent hose to the engine take. Install 2 zip ties securing the vent hose and fuel hose going to the carburetor.
Page 59 Muffler Installation (continued) g311099 Figure 47 14. Install the ground battery cable to the engine ground. 15. Install the positive battery cable to the starter. g311098 Figure 48 16. Connect the engine harness to the machine harness. PROLINE® Service Manual Page 4–29 Engine: Service and Repairs 3431-988 Rev A...
Page 60 Muffler Installation (continued) g311059 Figure 49 17. Install the deck belt to the PTO clutch. g311058 Figure 50 18. Install the spring to the deck idler. Engine: Service and Repairs Page 4–30 PROLINE® Service Manual 3431-988 Rev A...
Page 61 Muffler Installation (continued) g311057 Figure 51 19. Install the deck guard to the frame. Install the 2 pull-down straps to the deck guard. g310218 Figure 52 20. Connect the positive battery cable first, then the negative battery cable to the battery. Fuel Tank Assembly Replacement Fuel Tank Assembly Removal 1.
Page 62 Fuel Tank Assembly Removal (continued) 3. Drain all fuel from the fuel tank. 4. Remove the fuel tank supply hose and fuel tank vent hose from the fuel tank. 5. Remove the 2 bolts securing the fuel tank to the fuel tank support. 6.
Page 63 Chapter 5 Chassis Table of Contents General Information ..........................5–2 Service and Repairs ..........................5–3 36 Inch Caster Replacement......................5–7 Spindle Replacement......................... 5–9 PROLINE® Service Manual Page 5–1 Chassis 3431-988 Rev A...
Page 64 General Information There are three types of frames for this machine; 36 inch, 48–54 inch, and 60 inch. The 36 inch model will have a narrower frame than the larger models. It will also have different castor forks and wheels that are different than the larger frame.
Page 65 Service and Repairs Chassis Asm 1 (36 Inch Standard/Carb/International) g312018 Figure 53 Deck Cover Rubber Latch Frame Assembly PROLINE® Service Manual Page 5–3 Chassis: Service and Repairs 3431-988 Rev A...
Page 66 Chassis Asm 2 (48 Inch Standard/Carb/Premium/International) g312021 Figure 54 Rubber Latch Wide Deck Cover Frame Assembly Chassis: Service and Repairs Page 5–4 PROLINE® Service Manual 3431-988 Rev A...
Page 67 Chassis Asm 5 (54 Inch Standard/Premium) g312019 Figure 55 Rubber Latch Wide Deck Cover Frame Assembly PROLINE® Service Manual Page 5–5 Chassis: Service and Repairs 3431-988 Rev A...
Page 68 Chassis Asm 4 (60 Inch Standard) g312020 Figure 56 Frame Assembly Wide Deck Cover Rubber Latch Chassis: Service and Repairs Page 5–6 PROLINE® Service Manual 3431-988 Rev A...
Page 69 36 Inch Caster Replacement 36 Inch Caster Disassembly g318027 Figure 57 HHF Screw Flanged Bearing Washer Caster Fork Dust Cap HH Screw Thrust Washer Hex Nut 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key.
Page 70 48–54 and 60 Inch Caster Disassembly g318028 Figure 58 Grease Cap Grease Seal NI Lock Nut Caster Fork Bellville Washers HH Screw Tapered Roller Bearing Hex Nut 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key.
Page 71 48–54 and 60 Inch Assembly (continued) 2. Install the bearing into the wheel hub. 3. Install the grease seal into the wheel hub. 4. Repeat steps 1-3 for the opposite side. 5. Fill the center of the wheel hub with high temperature grease. 6.
Page 72 Spindle Removal (continued) 5. Use an appropriate lifting device, raise the machine off the floor to remove the cutting blade. 6. Remove the cutting blade from the machine. 7. Remove the 6 self-tapping bolts that secure the spindle to the deck. 8.
Page 73 Spindle Installation (continued) 3. Install the Belleville washer with the concave side facing the cutting blade. Install the blade bolt. Torque the blade bolt to 100-110 ft-lbs. (138-152 Nm). 4. Install the mower deck belt. 5. Install the mower belt covers. 6.
Page 74 Chassis: Service and Repairs Page 5–12 PROLINE® Service Manual 3431-988 Rev A...
Page 75 Chapter 6 Controls Table of Contents General Information ..........................6–2 Service and Repairs ..........................6–3 Park Brake Replacement ........................6–9 Choke Cable Replacement ......................6–14 Throttle Control Replacement ......................6–15 Control Handle Replacement ......................6–16 Reference Bar Replacement......................6–21 PROLINE® Service Manual Page 6–1 Controls 3431-988 Rev A...
Page 76 General Information The neutral setting and the tracking are adjusted with the control linkages. The adjustable reference bar is used to control the speed of machine. The operator can set the speed manually. Controls: General Information Page 6–2 PROLINE® Service Manual 3431-988 Rev A...
Page 77 Service and Repairs Controls Asm 1 (36 Inch) g312348 Figure 59 Damper Choke Cable RH Control Handle Asm Cover Plate Reference Bar Asm RH Control Rod Asm Tower Asm Bail Switch Throttle Control LH Control Handle Asm LH Control Rod Asm PROLINE®...
Page 78 Controls Asm 2 (48, 54, and 60 Inch) g312344 Figure 60 Damper Choke Cable RH Control Handle Asm Cover Plate Reference Bar Asm Control Rod Asm Tower Asm Bail Switch Throttle Control LH Control Handle Asm Controls: Service and Repairs Page 6–4 PROLINE®...
Page 79 Controls Asm 3 (48 and 54 Inch Premium) g312349 Figure 61 LH Control Handle Asm Choke Cable Reference Bar Asm Cover Plate Tower Asm RH Control Handle Asm Throttle Control Bail Switch Control Rod Asm LH Control Handle Asm PROLINE® Service Manual Page 6–5 Controls: Service and Repairs 3431-988 Rev A...
Page 80 Controls Asm 4 (36 Inch International) g312345 Figure 62 Damper Choke Cable Reference Bar Asm Cover Plate RH Control Handle Asm RH Control Rod Asm Tower Asm Bail Switch Throttle Control Plate Speed Limiter LH Control Rod Asm LH Control Handle Asm Controls: Service and Repairs Page 6–6 PROLINE®...
Page 81 Controls Asm 5 (48 Inch International) g312346 Figure 63 Damper LH Control Handle Asm RH Control Handle Asm Choke Cable Reference Bar Asm Cover Plate Control Rod Asm Bail Switch Tower Asm Speed Limiter Plate Throttle Control PROLINE® Service Manual Page 6–7 Controls: Service and Repairs 3431-988 Rev A...
Page 82 Controls Asm 6 g312347 Figure 64 Brake Asm Brake Cable Mount Bail Switch Brake Cable Cable Clamp Brake Cable Controls: Service and Repairs Page 6–8 PROLINE® Service Manual 3431-988 Rev A...
Page 83 Park Brake Replacement Park Brake Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery.
Page 84 Park Brake Removal (continued) 8. Remove the LH cotter pin and washer from the clevis pin on the brake arm on the hydro. Repeat for opposite side. g311244 Figure 67 Cotter Pin Clevis Pin Washer 9. Remove the transmission cable keeper from the transmission mount. Repeat for opposite side.
Page 85 Park Brake Removal (continued) g311222 Figure 69 11. Rotate the parking brake arm towards the operator and remove from the control tower. Park Brake Installation 1. Install the parking brake arm onto the control tower. 2. Install the 2 torx bolts securing the parking brake arm to the side of the control tower.
Page 86 Park Brake Installation (continued) g311221 Figure 71 4. Install the LH cotter pin and washer from the clevis pin on the brake arm on the hydro. Repeat for opposite side. g311244 Figure 72 5. Install the 2 parking brake cables to the parking brake arm. Controls: Service and Repairs Page 6–12 PROLINE®...
Page 87 Park Brake Installation (continued) g311220 Figure 73 6. Connect the parking brake switch to the wiring harness. g311219 Figure 74 7. Pull the brake arm up to add tension to the brake cable keeper. 8. Remove the blocks from the front and rear tires. 9.
Page 88 Choke Cable Replacement Choke Cable Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery.
Page 89 Choke Cable Installation (continued) g311104 Figure 76 6. Connect the positive battery cable first, then the negative battery cable to the battery. Throttle Control Replacement Throttle Control Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key.
Page 90 Throttle Control Removal (continued) 4. Remove the throttle cable from the throttle lever on the engine. 5. Cut the zip ties securing the throttle cable to the choke cable. 6. Remove the 2 bolts and nuts securing the throttle control to the control tower. 7.
Page 91 Control Handle Removal (continued) g311245 Figure 79 4. Cut the zip tie securing the wiring harness to the motion control. 5. Remove the bolt and nut securing the damper to the control tower. g311246 Figure 80 6. Remove the upper and lower control rods. 7.
Page 92 Control Handle Removal (continued) g311247 Figure 81 8. Remove the bolt securing the reference bar to the motion control arm. 9. Remove the 2 torx bolts the secure the motion control arm to the control tower. g311248 Figure 82 10. Remove the motion control arm from the control tower. 11.
Page 93 Control Handle Removal (continued) g311249 Figure 83 12. Remove the motion control arm from the machine. Control Handle Installation 1. Install the motion control arm onto the machine. Install the spring clip securing the damper to the motion control arm. g311249 Figure 84 2.
Page 94 Control Handle Installation (continued) g311248 Figure 85 4. Reapply Loctite. Install the bolt securing the reference bar to the motion control arm. Torque bolt to 6 N • m (53 ± 7 in-lb). 5. Install the bolt and nut securing the motion control arm to the control rod. Torque bolt and nut to 6 N •...
Page 95 Control Handle Installation (continued) g311246 Figure 87 7. Install a zip tie securing the wiring harness to the motion control. 8. Connect the wire harness from the operator’s presence switch to the motion control arm. g311245 Figure 88 9. Connect the positive battery cable first, then the negative battery cable to the battery.
Page 96 Reference Bar Removal (continued) 3. Remove the reference bar. Reference Bar Installation 1. Install the reference bar onto the machine. 2. Install the 2 bolts securing the reference bar to the machine. Torque to 6 N • m (57 ± 3 in-lb). Controls: Service and Repairs Page 6–22 PROLINE®...
Page 97 Chapter 7 Deck Table of Contents General Information ..........................7–2 Service and Repairs ..........................7–3 Deck Replacement..........................7–5 Deck Lift Assembly ..........................7–6 PROLINE® Service Manual Page 7–1 Deck 3431-988 Rev A...
Page 98 General Information On the deck there is an adjustable deck idler to add tension to the belt as it wears, adjustment is on the arm that holds the pulley through the slotted hold. It is recommended to check the deck idler yearly for wear. Deck: General Information Page 7–2 PROLINE®...
Page 99 Service and Repairs Deck Asm 1 (36 Inch) g312016 Figure 89 Pivot Asm 4–Link Deck Lift Chain HOC Pin Front Pivot Asm HOC Standoff Asm Deck Strut Asm Lock Lever Bearing Flange HOC Link Deck Lift Gusset Spacer PROLINE® Service Manual Page 7–3 Deck: Service and Repairs 3431-988 Rev A...
Page 100 Deck Asm 2 (48, 54 and 60 Inch) g312017 Figure 90 Pivot Asm Flange Bearing HOC Pin Deck Lift Gusset Lock Lever 4–Link Decklift Chain HOC Link Front Pivot Asm HOC Standoff Asm Deck Strut Asm Spacer Blower Hub Spacer Deck: Service and Repairs Page 7–4 PROLINE®...
Page 101 Deck Replacement Deck Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery.
Page 102 Deck Installation (continued) 4. Install the 4 bolts (2 bolts per side) on the chain connecting the deck strut and deck. Torque bolts to 40 N • m (30 ± 3 ft-lb). g311250 Figure 92 5. Install the mower deck belt. 6.
Page 103 Deck Lift Removal (continued) 13. Remove the bolt retaining the height-of-cut link to the rear pivot assembly. 14. Remove the height-of-cut link from the front and rear pivot assembly. 15. Remove the 3 Allen bolts and nuts from the height-of-cut stand-off assembly to the frame.
Page 104 Deck: Service and Repairs Page 7–8 PROLINE® Service Manual 3431-988 Rev A...
Page 105 Chapter 8 Drive System Table of Contents General Information ..........................8–2 Service and Repairs ..........................8–3 Transmission Replacement........................ 8–5 Hydrostatic Drive Belt Replacement....................8–11 Wheel and Tire Assembly Replacement ..................8–11 Transmission Oil Filter Replacement ....................8–12 Setting the Neutral Position ......................8–14 Tracking Adjustment ........................
Page 106 General Information There is no neutral setting assembly on the hydraulic transmissions. Moving the skids guard will help gain access to the hydro filters for maintenance. Drive System: General Information Page 8–2 PROLINE® Service Manual 3431-988 Rev A...
Page 107 Service and Repairs 36 Inch Drive Asm 1 g313849 Figure 93 Hydraulic Tank Extension Spring Expansion Tank Bracket V-Belt Overflow Hose Idler Arm Pivot Asm Overflow Hose LH ZT-2800 Transmission Rubber Grommet RH ZT-2800 Transmission Bypass Rod Hydro Cross Shaft Flat Idler Pulley PROLINE®...
Page 108 48, 54, and 60 Inch Drive Asm 2 g313850 Figure 94 Hydraulic Tank Flat Idler Pulley Expansion Tank Bracket Extension Spring Overflow Hose RH ZT-2800 Transmission Hydro Hose V-Belt Rubber Grommet Idler Arm Asm Idler Pulley Hydro Cross Shaft Bypass Rod LH ZT-2800 Transmission Drive System: Service and Repairs Page 8–4...
Page 109 Transmission Replacement Transmission Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery.
Page 110 Transmission Removal (continued) g312500 Figure 96 11. Install a 5/6 inch nut to lock the hydro lever in neutral position. 12. Remove the bolt and nut securing the motion control rod to the lever on the hydro. Remove the motion control rod from the lever on the hydro. 13.
Page 111 Transmission Removal (continued) g312502 Figure 98 15. Remove the bolt securing the crossmember to both transmissions. g312503 Figure 99 WARNING Heavy object, to avoid muscle strain or back injury, use lifting aids and proper lifting techniques when removing or replacing heavy objects.
Page 112 Transmission Installation WARNING Heavy object, to avoid muscle strain or back injury, use lifting aids and proper lifting techniques when removing or replacing heavy objects. 1. Using an appropriate lifting device, raise the transmission until able to connect the transmission reservoir hose to the top of the transmission. Continue to raise the transmission into position on the machine.
Page 113 Transmission Installation (continued) g312501 Figure 101 5. Install the motion control rod to the lever on the hydro. Install the bolt and nut securing the motion control rod to the lever on the hydro. g312506 Figure 102 6. Install the bypass arm. Install the cotter pin securing the bypass arm to the transmission.
Page 114 Transmission Installation (continued) g312500 Figure 103 8. Install the cotter pin to the clevis pin on the brake arm. 9. Set the parking brake to add tension to the brake arm. 10. Install the wheel onto the machine. 11. Using an appropriate lifting device, lower the rear of the machine onto the floor.
Page 115 Hydrostatic Drive Belt Replacement Hydrostatic Drive Belt Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the PTO belt from the PTO clutch. 3.
Page 116 Wheel and Tire Assembly Installation (continued) 3. Tighten the lug nuts on the wheel. Torque lug nuts to 108 N • m (80 ± 10 ft-lb). Transmission Oil Filter Replacement Transmission Oil Filter Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key.
Page 117 Transmission Oil Filter Removal (continued) 6. Remove the 2 bolts securing the guard to the transmission oil filter. 7. Drain all fluid from the machine. 8. Remove the transmission oil filter from the machine. Transmission Oil Filter Installation 1. Install the new transmission oil filter onto the machine. 2.
Page 118 Transmission Oil Filter Installation (continued) 7. Tighten the lug nuts on the wheel. Torque to 108 N • m (80 ± 10 ft-lb). g312499 Figure 109 Setting the Neutral Position 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key.
Page 119 Chapter 9 Electrical System Table of Contents General Information ..........................9–2 Service and Repairs ..........................9–3 Battery Replacement ......................... 9–5 Hour Meter Replacement ........................9–5 Ignition Switch Replacement......................9–7 PTO Switch Replacement ........................9–9 PTO Clutch Replacement ........................ 9–11 Solenoid Replacement........................9–13 PROLINE®...
Page 120 General Information The hour meter is programmed with an automatic shut-off. If the machine is parked with the engine running and the brake off, the machine will shut off within 5 seconds. The parking brake should be set anytime the operator leaves the machine.
Page 121 Service and Repairs Electrical Asm 1 (36, 48, 54, and 60 Inch) g312496 Figure 110 Hour Meter Module Solenoid On-Off Rocker Switch Negative Battery Cable Ignition Key Positive Battery Cable Ignition Switch Battery Hold Down Positive Battery Cable Pigtail Clutch Harness Wire Harness Battery PROLINE®...
Page 122 Electrical Asm 2 (48 and 54 Inch Premium) g312497 Figure 111 Hour Meter Module Battery Hold-Down On-Off Rocker Switch Positive Battery Cable Ignition Key Relay Ignition Switch Battery Wire Harness Pigtail Clutch Harness Negative Battery Cable Electrical System: Service and Repairs Page 9–4 PROLINE®...
Page 123 Battery Replacement Battery Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery.
Page 124 Hour Meter Removal (continued) 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery. 3. Disconnect the main wire harness from the hour meter. g312507 Figure 112 4. Press the tabs on the hour meter inward. 5.
Page 125 Hour Meter Installation (continued) g312507 Figure 114 3. Connect the positive battery cable first, then the negative battery cable to the battery. Ignition Switch Replacement Ignition Switch Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key.
Page 126 Ignition Switch Removal (continued) 5. Remove the ignition switch from the control tower. g312530 Figure 116 Ignition Switch Test 1. Remove the ignition switch from the control tower. 2. Using a digital multi-meter set to the OHM or continuity setting, verify that continuity exists between the terminals listed for each switch position.
Page 127 Ignition Switch Installation (continued) g312530 Figure 117 2. Connect the main wire harness to the ignition switch. g312529 Figure 118 3. Connect the positive battery cable first, then the negative battery cable to the battery. PTO Switch Replacement PTO Switch Removal 1.
Page 128 PTO Switch Removal (continued) g312562 Figure 119 4. Press the tabs on the PTO switch inward. PTO Switch Test g318278 Figure 120 1. Remove the PTO switch from the control tower. PTO Switch Replacement (page 9–9) 2. Using a digital multi-meter set to the OHM or continuity setting, verify the following: A.
Page 129 PTO Switch Test (continued) • Pins 2–4 should have continuity (closed) • Pins 7–8 should NOT have continuity (open) C. With the switch in the ON momentary position • Pins 2–4 should have continuity (closed) • Pins 7–8 should have continuity (closed) PTO Switch Installation 1.
Page 130 Coil Resistance Measurement Test (continued) 3. Set the multi-meter to measure resistance (OHMs setting). 4. Connect the meter lead wires to the terminals in the clutch connector. 5. See the PTO Clutch Electrical Specifications chart. Resistance (OHMs) Amp Draw Continuity to Ground 3.05 ±...
Page 131 Solenoid Replacement Solenoid Removal 1. Park the machine on a level surface and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Disconnect the battery by removing the negative battery cable first, then the positive cable from the battery.
Page 132 Electrical System: Service and Repairs Page 9–14 PROLINE® Service Manual 3431-988 Rev A...
Page 133 Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations......................A–2 Electrical Schematic...........................A–3 PROLINE® Service Manual Page A–1 Foldout Drawings 3431-988 Rev A...
Page 134 Electrical Drawing Abbreviations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. Abbreviation Color Black BR or BM Brown Blue Green Gray Orange Pink R or RD Violet W or WH White Y or YE Yellow...
Page 135 Electrical Schematic g318528 , Drawing Rev A, Sheet 1 3431-988 Rev A Page A–3...

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